Professional Diploma Course | Duration: 6 Months

Course Introduction

Process Safety Management (PSM) is a systematic approach to preventing major industrial accidents involving hazardous chemicals, flammable substances, toxic materials, pressure systems, and other high-risk industrial processes. It focuses on identifying, evaluating, controlling, and managing process-related hazards to prevent fires, explosions, toxic releases, equipment failures, and catastrophic incidents.

In modern industrial facilities, particularly chemical plants, pharmaceutical industries, petroleum refineries, gas processing plants, LPG facilities, power plants, fertilizer factories, and other process industries, effective Process Safety Management is essential for protecting workers, facilities, communities, and the environment.

This professional diploma programme provides participants with comprehensive knowledge and practical skills in process hazard identification, risk assessment, process safety engineering, operating procedures, mechanical integrity, management of change, emergency preparedness, incident investigation, and process safety auditing.

The programme also introduces internationally recognized Process Safety Management principles, including OSHA Process Safety Management (29 CFR 1910.119), Risk-Based Process Safety (RBPS), CCPS guidelines, HAZID, HAZOP, LOPA, Bow-Tie Analysis, and relevant ISO management system requirements.

Through structured modules, industrial case studies, practical assignments, and viva voce assessments, participants will develop the competencies required to support effective Process Safety Management systems in high-risk industrial environments.

Course Objectives

The main objectives of this programme are to:

• Understand the principles, scope, and importance of Process Safety Management.
• Identify major accident hazards associated with industrial processes.
• Develop skills in process hazard identification and risk assessment.
• Understand HAZID, HAZOP, LOPA, Bow-Tie Analysis, and other risk assessment techniques.
• Understand process safety engineering and safety-critical equipment requirements.
• Develop knowledge of safe operating procedures and process control.
• Understand Management of Change (MOC) and Process Safety Information (PSI).
• Apply mechanical integrity and inspection management principles.
• Strengthen emergency preparedness and major accident prevention.
• Develop competencies in process safety auditing and continual improvement.

Course Outcomes

After successful completion of the programme, participants will be able to:

• Explain the fundamentals and key elements of Process Safety Management.
• Identify process-related hazards and major accident scenarios.
• Conduct basic process hazard identification and risk assessment exercises.
• Understand and participate in HAZID and HAZOP studies.
• Apply risk evaluation techniques such as LOPA and Bow-Tie Analysis.
• Understand safe operating limits and critical process parameters.
• Explain the importance of mechanical integrity and safety-critical equipment.
• Apply MOC and pre-startup safety review principles.
• Support emergency response and incident investigation activities.
• Conduct basic process safety compliance inspections and audits.
• Contribute to the implementation and continual improvement of a PSM system.

Course Modules

Module 1: Fundamentals of Process Safety Management

Module Contents:

1. Introduction to Process Safety Management (PSM)
2. Difference Between Occupational Safety and Process Safety
3. Major Industrial Accidents: Fires, Explosions, Toxic Releases and Catastrophic Failures
4. Process Safety Culture, Leadership and Organizational Responsibilities
5. Overview of OSHA PSM, CCPS Risk-Based Process Safety and International Guidelines
6. Key Elements of an Effective Process Safety Management System

Assessment Requirements:

• Assignment Submission
• Viva Voce Test

Module 2: Process Hazard Identification and Risk Assessment

Module Contents:

1. Process Hazard Identification (HAZID) and Hazard Analysis Principles
2. Hazard and Operability Study (HAZOP): Objectives, Methodology and Guide Words
3. Process Risk Assessment and Risk Ranking Matrix
4. Layer of Protection Analysis (LOPA) and Safety Instrumented Systems (SIS) Fundamentals
5. Bow-Tie Analysis, Fault Tree Analysis and Event Tree Analysis
6. Risk Reduction Measures, Safeguards and ALARP Principles

Assessment Requirements:

• Assignment Submission
• Viva Voce Test

Module 3: Process Safety Information and Operational Control

Module Contents:

1. Process Safety Information (PSI): Chemical, Process and Equipment Information
2. Chemical Properties, Toxicity, Flammability and Reactivity Hazards
3. Process Flow Diagrams (PFD), Piping and Instrumentation Diagrams (P&ID)
4. Safe Operating Procedures and Critical Operating Parameters
5. Permit-to-Work System, Isolation, Lockout/Tagout (LOTO) and Confined Space Controls
6. Operating Discipline, Process Monitoring and Abnormal Situation Management

Assessment Requirements:

• Assignment Submission
• Viva Voce Test

Module 4: Mechanical Integrity and Process Safety Engineering

Module Contents:

1. Mechanical Integrity Programme and Safety-Critical Equipment Management
2. Inspection, Testing and Preventive Maintenance of Process Equipment
3. Pressure Vessels, Boilers, Pipelines, Pumps, Compressors and Storage Tanks
4. Pressure Relief Devices, Safety Valves and Emergency Shutdown Systems
5. Process Control Systems, Instrumentation and Safety Instrumented Functions
6. Corrosion, Erosion, Equipment Failure and Reliability Management

Assessment Requirements:

• Assignment Submission
• Viva Voce Test

Module 5: Management of Change, Emergency Preparedness and Incident Investigation

Module Contents:

1. Management of Change (MOC): Technical, Organizational and Procedural Changes
2. Pre-Startup Safety Review (PSSR) and Safe Commissioning Requirements
3. Emergency Planning and Response for Fire, Explosion and Toxic Release
4. Industrial Incident, Near-Miss and Major Accident Investigation
5. Root Cause Analysis (RCA), Failure Analysis and Corrective Actions
6. Emergency Drills, Business Continuity and Lessons Learned

Assessment Requirements:

• Assignment Submission
• Viva Voce Test

Module 6: Process Safety Auditing, Compliance and Continual Improvement

Module Contents:

1. Process Safety Management Auditing: Principles, Scope and Methodology
2. PSM Compliance Evaluation and Gap Assessment
3. Process Safety Performance Indicators and Leading/Lagging Metrics
4. Contractor Safety Management, Training and Employee Participation
5. Process Safety Documentation, Records and Management Review
6. PSM System Improvement, Action Tracking and Integration with ISO 45001 and ISO 14001

Assessment Requirements:

• Assignment Submission
• Viva Voce Test

Course Methodology

The programme will be delivered through a combination of:

• Professional instructor-led training sessions.
• PowerPoint-based theoretical and technical discussions.
• Industrial case studies on major process safety incidents.
• Practical exercises on HAZID, HAZOP and risk assessment.
• Risk assessment matrix and Bow-Tie Analysis exercises.
• Process safety documentation and checklist development.
• Group discussions and problem-solving activities.
• Assignments and module-based assessments.
• Final viva voce assessment.

Who Should Attend?

This professional diploma programme is suitable for:

• Process Safety Officers and Engineers.
• Health, Safety and Environment (HSE) Professionals.
• Industrial Safety Managers and Coordinators.
• Chemical and Process Engineers.
• Production and Operations Managers.
• Plant and Maintenance Engineers.
• Mechanical and Electrical Engineers.
• Pharmaceutical and Chemical Industry Professionals.
• Petroleum, Oil, Gas and LPG Industry Professionals.
• Power Plant and Fertilizer Industry Professionals.
• Risk Assessment and Compliance Professionals.
• Internal Auditors and Management System Professionals.
• Industrial Consultants and Technical Advisors.
• Professionals responsible for hazardous process operations.

Course Conclusion

Process Safety Management is a critical component of industrial risk management and major accident prevention. Effective implementation of PSM helps organizations prevent catastrophic incidents, protect employees and surrounding communities, maintain operational reliability, and ensure responsible management of hazardous industrial processes.

This six-month professional diploma programme is designed to develop practical knowledge and professional competencies in process hazard analysis, risk assessment, operational control, mechanical integrity, management of change, emergency preparedness, incident investigation, and process safety auditing.

By completing this programme, participants will be better prepared to contribute to the development, implementation, monitoring, and continual improvement of Process Safety Management systems in high-risk industrial facilities.

Course Information

• Course Title: Diploma in Process Safety Management (PSM)
• Course Type: Professional Diploma Course
• Duration: 6 Months
• Programme Structure: 6 Modules
• Assessment: Module Assignments and Viva Voce Tests
• Training Provider: Compliance Training (BD) Limited (CTBL)
• Certificate: Professional Diploma Certificate upon successful completion of the programme and applicable assessment requirements.

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